Protective face mask

ABSTRACT

A protective face mask may comprise an outer housing including a plurality of ventilation holes, and an inner housing detachably coupled to the outer housing, the inner housing configured to cover a nose and a mouth of a user, the inner housing including a second plurality of ventilation holes. The protective face mask may also include a replaceable filter configured to be received in a space between the inner housing and the outer housing. In some embodiments, the protective face mask includes a dual chamber breathing design configured to reduce moisture collection within the mask.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication No. 63/005,302; filed Apr. 4, 2020; entitled FACE MASK; andhaving an attorney docket number SCALISI.010P.

BACKGROUND Field

Various embodiments disclosed herein relate to protective face masks.Certain embodiments relate to protective face masks including a dualbreathing chamber.

Description of Related Art

Protective face masks can prevent the spread of illness by providing abarrier between the external environment and a mouth and nose of a user.Protective face masks may also filter the air breathed by the user.Protective face masks often cover the lower portion of the user's faceand are secured with a strap(s) and/or tie(s). The strap(s) and/ortie(s) may go around a user's head, or may secure around the user'sears. Protective face masks may be worn by healthcare workers, anyoneworking in an environment with large amounts of particulate matter inthe air (e.g., firefighters, construction workers, etc.), and anyone inthe general public who desires protection from pollution and/or illness.

SUMMARY

The disclosure includes a protective face mask, and in some embodiments,the protective face mask includes an outer housing including a pluralityof ventilation holes, and an inner housing detachably coupled to theouter housing, the inner housing configured to cover a nose and a mouthof a user, the inner housing including a second plurality of ventilationholes, wherein a space between the inner housing and the outer housingis configured to receive a replaceable filter. The inner housing maycomprise a partition configured to divide the inner housing into anupper chamber and a lower chamber.

In some embodiments, when the mask is coupled to a face of the user, thepartition is configured to be located below the nose of the user andabove the mouth of the user. The partition may comprise a siliconeovermold. In some embodiments, the silicone overmold is furtherconfigured to form a seal against a face of the user. The upper chambermay be configured to receive the nose of the user and the lower chambermay be configured to receive the mouth of the user. In some embodiments,the division of the inner housing into the upper chamber and the lowerchamber is configured to reduce moisture collection on the replaceablefilter.

The outer housing may be configured to receive the inner housing via afriction fit. In some embodiments, the outer housing is configured toreceive the inner housing via a channel lock. The outer housing maycomprise a female portion of the channel lock that extends around aninner perimeter of the outer housing, and the inner housing may comprisea male portion of the channel lock that extends around an outerperimeter of the inner housing.

In some embodiments, the outer housing and the inner housing comprise amaterial configured to impart at least one of anti-bacterial,anti-viral, and anti-fungal properties to the protective face mask. Thematerial may comprise silver nanoparticles.

In some embodiments, the outer housing comprises a first aperturelocated along a first side of the outer housing and a second aperturelocated along a second side of the outer housing located opposite thefirst side, wherein the first aperture and second aperture areconfigured to receive a strap. The strap may comprise a material that isconfigured to stretch and an adjusting mechanism configured to adjust alength of the strap. In some embodiments, the material includes silvernanoparticles.

The replaceable filter may comprise four layers. In some embodiments,the four layers comprise a first sealed filter, a flux filter, a carbonfilter, and a second sealed filter. The outer housing may define a firstwidth and the inner housing may define a second width, wherein the firstwidth is larger than the second width.

In some embodiments, each hole in the first plurality of ventilationholes defines a first area and each hole in the second plurality ofventilation holes defines a second area, wherein the second area islarger than the first area. Each hole in the first plurality ofventilation holes may define a shape that is at least one ofsubstantially round and substantially ovoid. Each hole in the secondplurality of ventilation holes may define a shape that is substantiallyhexagonal.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages are described belowwith reference to the drawings, which are intended to illustrate, butnot to limit, the invention. In the drawings, like reference charactersdenote corresponding features consistently throughout similarembodiments.

FIG. 1 illustrates a perspective view of a user wearing a face mask,according to some embodiments.

FIG. 2 illustrates a front perspective view of a face mask, according tosome embodiments.

FIG. 3 illustrates a back perspective view of a face mask, according tosome embodiments.

FIG. 4 illustrates a front view of a face mask, according to someembodiments.

FIG. 5 illustrates a cross-sectional view of a face mask being worn by auser, according to some embodiments.

FIG. 6 illustrates a back view of a face mask, according to someembodiments.

FIG. 7 illustrates a side view of a face mask, according to someembodiments.

FIGS. 8A and 8B illustrate top and bottom views, respectively, of a facemask, according to some embodiments.

FIGS. 9 and 10 illustrate exploded views of a face mask, according tosome embodiments.

FIG. 11 illustrates a perspective view of a face mask with a strap,according to some embodiments.

FIG. 12 illustrates layers of a filter of a face mask, according to someembodiments.

FIG. 13 illustrates the relative widths of an inner housing and an outerhousing of a face mask, according to some embodiments.

DETAILED DESCRIPTION

Although certain embodiments and examples are disclosed below, inventivesubject matter extends beyond the specifically disclosed embodiments toother alternative embodiments and/or uses, and to modifications andequivalents thereof. Thus, the scope of the claims appended hereto isnot limited by any of the particular embodiments described below. Forexample, in any method or process disclosed herein, the acts oroperations of the method or process may be performed in any suitablesequence and are not necessarily limited to any particular disclosedsequence. Various operations may be described as multiple discreteoperations in turn, in a manner that may be helpful in understandingcertain embodiments; however, the order of description should not beconstrued to imply that these operations are order dependent.Additionally, the structures, systems, and/or devices described hereinmay be embodied as integrated components or as separate components.

For purposes of comparing various embodiments, certain aspects andadvantages of these embodiments are described. Not necessarily all suchaspects or advantages are achieved by any particular embodiment. Thus,for example, various embodiments may be carried out in a manner thatachieves or optimizes one advantage or group of advantages as taughtherein without necessarily achieving other aspects or advantages as mayalso be taught or suggested herein.

COMPONENT INDEX

-   10—face mask-   12—outer housing-   14—first plurality of ventilation holes-   16—inner housing-   18—nose-   20—mouth-   22—user-   24—second plurality of ventilation holes-   28—replaceable filter-   30—partition-   32—upper chamber-   34—lower chamber-   36—overmold-   38—female portion of channel lock-   40—male portion of channel lock-   42—inner perimeter (of outer housing)-   44—outer perimeter (of inner housing)-   48—aperture-   50—first side-   52—second side-   54—strap-   56—adjusting mechanism-   58—layers of filter-   58 a—first sealed filter-   58 b—flux filter-   58 c—carbon filter-   58 d—second sealed filter-   60—first width-   62—second width

FIG. 1 shows a user 22 wearing a face mask 10. It should be noted thatthroughout this disclosure, the terms “face mask”, “mask”, and“protective face mask” may be used interchangeably. The user 22 is shownwearing the face mask 10 such that it covers much of the lower half ofthe user's face, including the user's nose and mouth. The amount of theuser's 22 face covered by the mask 10 may depend on a shape and/or sizeof the user's 22 face. FIG. 1 also includes a strap 54, which in manyembodiments, is used to couple the face mask 10 to the face of the user22. The strap 54 may be configured to wrap around the head of the user22, as shown in FIG. 1 and FIG. 11, which will be discussed in greaterdetail later in the disclosure. In some embodiments, the strap 54comprises two loop-style straps designed to hook around the ears of theuser 22. The strap 54 may be a continuous piece of material or aplurality of individual pieces of material. Additional properties of thestrap 54 will be discussed with reference to FIG. 11.

FIG. 2 illustrates a front perspective view of the face mask 10,according to some embodiments. As shown in FIG. 2, the face mask 10 mayinclude an outer housing 12 and an overmold 36. The overmold 36 may becoupled to the outer housing 12 via an inner housing 16, as will bediscussed later in this disclosure. In many embodiments, the outerhousing 12 includes a first plurality of ventilation holes 14. Asillustrated in FIG. 2, each hole in the first plurality of ventilationholes 14 may be substantially ovoid in shape. In some embodiments, eachhole is substantially circular. Each hole in the first plurality ofventilation holes 14 may be any suitable shape. Though FIG. 2 shows theface mask 10 including a solid band with no ventilation holes extendingacross a center portion of the outer housing 12, in some embodiments,substantially an entire surface of the outer housing 12 includes thefirst plurality of ventilation holes 14.

FIG. 2 also includes an aperture 48. In many embodiments, the aperture48 is configured to receive at least part of a strap 54 to therebyenable coupling of the face mask 10 to the face of a user 22. FIG. 2also shows the face mask 10 including an upper curved portion thatextends above the main body of the face mask 10. In some embodiments,this upper curved portion is configured to cover the nose of the user22. This feature may provide a comfortable fit and strong seal againstthe face of the user 22. In some embodiments, the face mask 10 includingthe upper curved portion is especially designed for use by healthcareworkers or others exposed to germs, pollution, and the like at highvolumes. The embodiment of the face mask 10 shown in the figures may beconsidered a “professional protective face mask” and/or a “commercialprotective face mask”. In some embodiments, the face mask 10 does notinclude the upper curved portion, and instead resembles a moresymmetrical curved shape, where a top portion of the mask substantiallyreflects a bottom portion of the mask. The face mask 10 may be sized tofit a child. In some embodiments, a child-size face mask 10 isconfigured to fit an average-sized child up to about 10 years old.

FIG. 3 illustrates a back perspective view of the face mask 10,according to some embodiments. As shown, the face mask 10 may includethe outer housing 12, shown in FIGS. 1 and 2, as well as an innerhousing 16. In many embodiments, the face mask 10 also includes anovermold 36, which in turn includes a partition 30 configured toseparate the inner housing 16 into a dual breathing chamber comprisingtwo ventilation channels: an upper chamber 32 and a lower chamber 34.The partition 30 may be configured to sit against an area above theupper lip of the user 22 below the nostrils, such that the upper chamber32 may be configured to receive the nose of a user 22, and the lowerchamber 34 may be configured to receive the mouth of the user 22. Inmany embodiments, separating the nose and mouth of the user 22 reducesmoisture collection in the mask, as inhalation and exhalation occur inseparate chambers. In addition, most of the moisture collected in themask may be concentrated to the chamber receiving exhalation (e.g., thelower chamber 34 when the user 22 is exhaling through their mouth). Thismay enable the inhalation chamber (e.g., the upper chamber 32 when theuser 22 inhales through their nose) to remain completely or nearlycompletely dry.

Using a dual breathing chamber and reducing moisture collection mayprovide a more comfortable mask-wearing experience for the user 22. Inmany embodiments of using a traditional face mask, users are forced tore-inhale air that was recently exhaled. In addition to the generaldiscomfort this may cause (e.g., breathing in warm, moist, potentiallyodorous air), recently exhaled air is higher in carbon dioxide than“fresh” air, and inhaling carbon dioxide in excessive amounts can beharmful to health. As previously stated, the chamber used for inhalationmay remain dry, thus enabling the user 22 to inhale fresh, dry airrather than stale and/or damp air. The dual breathing chamber may alsoprovide other benefits, including but not limited to: faster airflowcirculation, less obstruction in breathing, reduced “fogging” of glassesworn by the user 22, a general fresh and/or dry feeling on at least aportion of the user's 22 face covered by the mask 10, and preventing thespread of germs via droplets.

As will be discussed in greater detail with reference to FIG. 12, insome embodiments the face mask 10 includes a replaceable filter. Thedual breathing chamber may extend the amount of time that thereplaceable filter is effective by reducing the amount of moisturecollected on the filter. For example, under heavy use (e.g., in ahealthcare setting), the replaceable filter may last about 2 or 3 days.Under everyday use (e.g., a member of the general public wearing a maskfor shorter periods of time, such as when running errands), thereplaceable filter may last about 5 days.

In many embodiments, the overmold 36 shown in FIG. 3 comprises a pieceof silicone overmolded onto the inner housing 16. The silicone maycomprise soft fitted silica gel, which may provide a comfortable andflexible fit to the face of the user 22. A flexible fit of the overmold36 may enable users 22 of varied face shapes and/or sizes to comfortablywear the face mask 10. In some embodiments, the silicone comprises 8 mmsilicone. The overmold 36 may be configured to form a seal on the faceof the user 22. In some embodiments, the seal contributes to thelongevity of the replaceable filter and general effectiveness of themask 10 by substantially eliminating the entrance of air—includingbacteria, viruses, pollutants, and the like—into the mask 10 through anyportion other than the first plurality of ventilation holes 14 on theouter housing 12.

FIG. 3 also illustrates the second plurality of ventilation holes 24. Asshown, each hole in the second plurality of ventilation holes 24 maydefine a substantially hexagonal shape. Each hole may also define asubstantially octagonal, pentagonal, heptagonal, rectangular, or anyother suitable shape. In some embodiments, and as can be seen whencomparing FIG. 2 and FIG. 3, each hole in the second plurality ofventilation holes 24 may define a larger area than each hole in thefirst plurality of ventilation holes 14.

FIG. 4 shows a front view of a face mask 10, according to someembodiments. Similar to FIG. 2, FIG. 4 includes the outer housing 12 andthe first plurality of ventilation holes 14. FIG. 4 expands on theaperture 48 shown in FIG. 2 by including both a first aperture 48 a anda second aperture 48 b. In some embodiments, the first aperture 48 a iscoupled to a first side 50 of the outer housing 12, and the secondaperture 48 b is coupled to a second side 52 of the outer housing 12. Aspreviously discussed, the apertures 48 a, 48 b may be configured toreceive a portion of a strap 54 (not shown) in order to enable couplingthe mask 10 to the face of a user 22. In some embodiments, each aperture48 a, 48 b is configured to receive individual straps configured to looparound the ears of the user 22. FIG. 4 also includes a dashed lineextending down substantially the middle of the face mask 10 with a noteto see FIG. 5, indicating a cross-sectional view.

FIG. 5 illustrates the cross-sectional view of the face mask 10 locatedon a user 22, drawn in profile. FIG. 5 shows that, in some embodimentsand as discussed with reference to FIG. 3, the partition 30 is locatedabove the mouth 20 and below the nose 18 of the user 22. The partition30 thereby separates the face mask 10 into an upper chamber 32, shownreceiving the nose 18, and a lower chamber 34, shown receiving the mouth20. It should be noted that though the user 22 is illustrated in FIG. 5as inhaling through their nose 18 and exhaling through their mouth 20,the inverse is possible and may be practiced while wearing the face mask10. It should also be noted that the face mask 10 may cover less, more,or substantially the same amount of the face of the user 22 illustratedin FIG. 5. As previously mentioned, in many embodiments, the mask 10 isconfigured to fit comfortably on a variety of face shapes and sizes, sothe portion of a user's 22 face covered by the mask 10 may depend on theuser's 22 face shape and/or size.

FIG. 6 shows a back view of the face mask 10, including the outerhousing 12, the inner housing 16, and the partition 30. FIG. 6 alsoillustrates that, in many embodiments, the face mask includes areplaceable filter 28. When the inner housing 16 is coupled to the outerhousing 12, the replaceable filter 28 may be located in a space betweenthe inner housing 16 and the outer housing 12. The replaceable filter 28will be discussed in more detail with reference to FIG. 12. FIG. 6 alsoincludes the first aperture 48 a and the second aperture 48 b.

FIG. 7 illustrates a side view of the face mask 10, according to someembodiments. As shown, the face mask 10 may have a generally curvedshape in order to accommodate the nose 18 and mouth 20 of the user 22that are received within the mask 10, as shown in FIG. 5. FIG. 7 alsoshows the first aperture 48 a. I should be noted that the first aperture48 a, as well as the second aperture 48 b, may comprise a form and/orshape different than what is shown in the Figures. For example, theapertures 48 a, 48 b may comprise hooks or other such mechanismsdesigned to retain at least a portion of a strap (or straps) 54. FIGS.8A and 8B illustrate top and bottom views, respectively, of the facemask 10, according to some embodiments. As also shown in FIG. 7, FIGS.8A and 8B illustrate the curved nature of the face mask 10. Though notlabeled, the mask 10 shown in FIGS. 8A and 8B includes the overmold 36.In some embodiments, the face mask 10 does not include the overmold 36.

FIGS. 9 and 10 show exploded top and front views, respectively, of theface mask 10, according to some embodiments. As shown in FIGS. 9 and 10and as discussed with reference to the other Figures, the face mask 10may include an overmold 36, an inner housing 16, a replaceable filter28, and an outer housing 12. As previously discussed, in someembodiments the overmold 36 comprises a soft silicone molded onto theinner housing 16. The overmold 36 may be configured to be molded to aninterior portion, including an inner perimeter, of the inner housing 16.Alternatively, the overmold 36 may be configured to be molded to anexterior portion of the inner housing 16.

In many embodiments, the inner housing 16 and the outer housing 12comprise an at least semi-rigid material, such as plastic. In someembodiments, the plastic is bisphenol A (“BPA”) free for user safety.The housings 12, 16 may comprise polypropylene (“PP”) plastic. In manyembodiments, the housings 12, 16 comprise acrylonitrile butadienestyrene (“ABS”) plastic. Whether comprising PP or ABS plastic, or acombination thereof, in some embodiments the material of the housings12, 16 includes embedded silver nanoparticles. In many embodiments, theintegration of silver nanoparticles into the housings 12, 16 imparts atleast one of anti-bacterial, anti-viral, and anti-fungal properties tothe face mask 10. In some embodiments, the material composition includesat least 1% silver nanoparticles of the total composition. In someembodiments, the material composition includes less than 1% silvernanoparticles. In some embodiments, the material composition includesless than 0.1% silver nanoparticles. In some embodiments, the materialcomposition includes less than 0.01% silver nanoparticles. In addition,the housings 12, 16 may be able to be washed, such as with warm waterand soap, or rinsed, such as with rubbing alcohol, and re-used withoutbreakdown of the housing material. The re-usable nature of the face mask10 may reduce the amount of waste produced in particular industries, andby the general public, especially when compared to traditionalsingle-use masks. In addition, the face mask 10 may presentsignificantly lower monthly costs than traditional single-use masks.

In some embodiments, the outer housing 12 is configured to detachablyreceive the inner housing 16 via a friction fit. As previouslymentioned, the replaceable filter 28 may be located between the outerhousing 12 and the inner housing 16 when the housings are coupledtogether. In some embodiments, the outer housing 12 is configured todetachably couple to the inner housing 16 via a channel lock. FIG. 9shows that, according to some embodiments, the inner housing 16 includesa male portion of the channel lock 40 and the outer housing 12 includesa female portion of the channel lock 38. The male portion 40 may belocated along an outer perimeter 44 of the inner housing 16, and thefemale portion 38 may be located along an inner perimeter 42 of theouter housing 12, as illustrated in FIG. 9. As such, the female portion38 may be configured to receive the male portion 40, thereby detachablycoupling the outer perimeter 44 of the inner housing 16 to the innerperimeter 42 of the outer housing 12. FIG. 10 also shows the maleportion 40 located along the outer perimeter 44 of the inner housing 16.

FIG. 11 shows another perspective view of the face mask 10, and includesthe strap 54 and an adjusting mechanism 56. As previously discussed,different forms of the strap 54 are possible. FIG. 11 illustrates that,in some embodiments, the strap 54 comprises a continuous strapconfigured to use at least one aperture 48 to form two loops around theback of the head of a user 22. The adjusting mechanism 56 may be used toadjust the fit of the mask 10 by shortening and/or lengthening the strap54. In some embodiments, the strap 54 comprises a stretchy material. Thematerial may comprise nylon, elastic, another suitable material, or anycombination thereof. Similar to the material comprising the inner andouter housings 12, 16, the strap 54 material may include silvernanoparticles to impart at least one of anti-bacterial, anti-viral, andanti-fungal properties onto the strap 54.

FIG. 12 illustrates the layers 58 of the replaceable filter 28. In someembodiments, and as shown in FIG. 12, the layers 58 include four layerscomprising a first sealed filter 58 a, a flux filter 58 b, a carbonfilter 58 c, and a second sealed filter 58 d. The flux filter 58 b maycomprise a 2.5 micron filter. As previously mentioned, the replaceablefilter 28 may be wearable for about 3 days under heavy use and for about5 days under light, everyday use. Each layer 58 of the filter 28 maycomprise a soft material, and as such, the filter 28 may comprise asoft, flexible combination of materials. In some embodiments, the filter28 is disposable. By embedding at least one layer 58 with silvernanoparticles, the filter 28 may have similar anti-bacterial,anti-viral, and/or anti-fungal properties as compared to the outer andinner housings 12, 16, and the strap 54. In some embodiments, the filter28 is available in different sizes. For example, a child-size face mask10 may require a different size replaceable filter 28 than an adult-sizeface mask 10.

FIG. 13 includes the outer housing 12 and the inner housing 16, andillustrates their respective widths. In some embodiments, a first width60 of the outer housing 12 is larger than a second width 62 of the innerhousing 16. The relative sizes of each of the housings 12, 16 is alsoshown in FIGS. 9 and 10 and discussed with reference to how the housings12, 16 detachably couple together; the outer perimeter 44 of the innerhousing 16 couples to the inner perimeter 42 of the outer housing 12 viathe channel lock.

In some embodiments, the face mask 10 is KN95 certified. The face mask10 may also be FDA approved and SGS tested. The face mask 10 may also becustomizable and available in a variety of colors and/or patterns.

Interpretation

None of the steps described herein is essential or indispensable. Any ofthe steps can be adjusted or modified. Other or additional steps can beused. Any portion of any of the steps, processes, structures, and/ordevices disclosed or illustrated in one embodiment, flowchart, orexample in this specification can be combined or used with or instead ofany other portion of any of the steps, processes, structures, and/ordevices disclosed or illustrated in a different embodiment, flowchart,or example. The embodiments and examples provided herein are notintended to be discrete and separate from each other.

The section headings and subheadings provided herein are nonlimiting.The section headings and subheadings do not represent or limit the fullscope of the embodiments described in the sections to which the headingsand subheadings pertain. For example, a section titled “Topic 1” mayinclude embodiments that do not pertain to Topic 1 and embodimentsdescribed in other sections may apply to and be combined withembodiments described within the “Topic 1” section.

Some of the devices, systems, embodiments, and processes use computers.Each of the routines, processes, methods, and algorithms described inthe preceding sections may be embodied in, and fully or partiallyautomated by, code modules executed by one or more computers, computerprocessors, or machines configured to execute computer instructions. Thecode modules may be stored on any type of non-transitorycomputer-readable storage medium or tangible computer storage device,such as hard drives, solid state memory, flash memory, optical disc,and/or the like. The processes and algorithms may be implementedpartially or wholly in application-specific circuitry. The results ofthe disclosed processes and process steps may be stored, persistently orotherwise, in any type of non-transitory computer storage such as, e.g.,volatile or non-volatile storage.

The various features and processes described above may be usedindependently of one another, or may be combined in various ways. Allpossible combinations and subcombinations are intended to fall withinthe scope of this disclosure. In addition, certain method, event, state,or process blocks may be omitted in some implementations. The methods,steps, and processes described herein are also not limited to anyparticular sequence, and the blocks, steps, or states relating theretocan be performed in other sequences that are appropriate. For example,described tasks or events may be performed in an order other than theorder specifically disclosed. Multiple steps may be combined in a singleblock or state. The example tasks or events may be performed in serial,in parallel, or in some other manner. Tasks or events may be added to orremoved from the disclosed example embodiments. The example systems andcomponents described herein may be configured differently thandescribed. For example, elements may be added to, removed from, orrearranged compared to the disclosed example embodiments.

Conditional language used herein, such as, among others, “can,” “could,”“might,” “may,” “e.g.,” and the like, unless specifically statedotherwise, or otherwise understood within the context as used, isgenerally intended to convey that certain embodiments include, whileother embodiments do not include, certain features, elements and/orsteps. Thus, such conditional language is not generally intended toimply that features, elements and/or steps are in any way required forone or more embodiments or that one or more embodiments necessarilyinclude logic for deciding, with or without author input or prompting,whether these features, elements and/or steps are included or are to beperformed in any particular embodiment. The terms “comprising,”“including,” “having,” and the like are synonymous and are usedinclusively, in an open-ended fashion, and do not exclude additionalelements, features, acts, operations and so forth. Also, the term “or”is used in its inclusive sense (and not in its exclusive sense) so thatwhen used, for example, to connect a list of elements, the term “or”means one, some, or all of the elements in the list. Conjunctivelanguage such as the phrase “at least one of X, Y, and Z,” unlessspecifically stated otherwise, is otherwise understood with the contextas used in general to convey that an item, term, etc. may be either X,Y, or Z. Thus, such conjunctive language is not generally intended toimply that certain embodiments require at least one of X, at least oneof Y, and at least one of Z to each be present.

The term “and/or” means that “and” applies to some embodiments and “or”applies to some embodiments. Thus, A, B, and/or C can be replaced withA, B, and C written in one sentence and A, B, or C written in anothersentence. A, B, and/or C means that some embodiments can include A andB, some embodiments can include A and C, some embodiments can include Band C, some embodiments can only include A, some embodiments can includeonly B, some embodiments can include only C, and some embodiments caninclude A, B, and C. The term “and/or” is used to avoid unnecessaryredundancy.

The term “substantially” is used to mean “completely”, “nearlycompletely”, “exactly”, or “nearly exactly”. For example, the disclosureincludes “in some embodiments, substantially an entire surface of theouter housing 12 includes the first plurality of ventilation holes 14”.In this context, the term “substantially” indicates thatcompletely/exactly or nearly completely/exactly the entire surface ofthe outer housing includes the first plurality of ventilation holes.

The term “about” is used to mean “approximately”. For example, thedisclosure includes “In some embodiments, a child-size face mask 10 isconfigured to fit an average-sized child up to about 10 years old.” Inthis context, the child-size mask is configured to fit a child up toapproximately 10 years old. A child between 8 and 12 years old may fallinto the range of “about 10 years old” in the context of thisdisclosure.

While certain example embodiments have been described, these embodimentshave been presented by way of example only, and are not intended tolimit the scope of the inventions disclosed herein. Thus, nothing in theforegoing description is intended to imply that any particular feature,characteristic, step, module, or block is necessary or indispensable.Indeed, the novel methods and systems described herein may be embodiedin a variety of other forms; furthermore, various omissions,substitutions, and changes in the form of the methods and systemsdescribed herein may be made without departing from the spirit of theinventions disclosed herein.

1. A protective face mask, comprising: an outer housing including afirst plurality of ventilation holes, wherein the first plurality ofventilation holes allow for air ingress and egress; a replaceable filterremovably coupled to the outer housing, wherein the replaceable filteris configured to substantially cover each hole of the first plurality ofventilation holes; an inner housing detachably coupled to the outerhousing, the inner housing configured to cover a nose and a mouth of auser, the inner housing including a second plurality of ventilationholes defining a first portion and a second portion, and a soliddividing line that extends between the first portion and the secondportion, wherein the solid dividing line defines an upper chamberincluding the first portion of the second plurality of ventilation holesand a lower chamber including the second portion of the second pluralityof ventilation holes, wherein the replaceable filter is removablycoupled between the outer housing and the inner housing, and whereineach of the first portion of the second plurality of ventilation holesand the second portion of the second plurality of ventilation holesallow for air ingress and egress; and an overmold removably coupled tothe inner housing, whereby the replaceable filter and the inner housingare located between the outer housing and the overmold, the overmoldincluding a partition extending between the first portion of the secondplurality of ventilation holes and the second portion of the secondplurality of ventilation holes, wherein when the protective face mask isworn by a user, the partition physically contacts the user between thenose and the mouth and extends substantially an entire width of theinner housing of the protective face mask.
 2. (canceled)
 3. (canceled)4. The protective face mask of claim 1, wherein the overmold comprises asilicone overmold.
 5. The protective face mask of claim 4, wherein thesilicone overmold is further configured to form a seal against a face ofthe user.
 6. The protective face mask of claim 1, wherein the upperchamber is configured to receive the nose of the user and the lowerchamber is configured to receive the mouth of the user.
 7. Theprotective face mask of claim 6, wherein a division, via the partition,of the inner housing into the upper chamber and the lower chamber isconfigured to reduce moisture collection on the replaceable filter. 8.The protective face mask of claim 1, wherein the outer housing isconfigured to receive the inner housing via a friction fit.
 9. Theprotective face mask of claim 1, wherein the outer housing is configuredto receive the inner housing via a channel lock.
 10. The protective facemask of claim 9, wherein the outer housing comprises a female portion ofthe channel lock that extends around an inner perimeter of the outerhousing and the inner housing comprises a male portion of the channellock that extends around an outer perimeter of the inner housing. 11.The protective face mask of claim 1, wherein the outer housing and theinner housing comprise a material configured to impart at least one ofanti-bacterial, anti-viral, and anti-fungal properties to the protectiveface mask.
 12. The protective face mask of claim 11, wherein thematerial comprises silver nanoparticles.
 13. The protective face mask ofclaim 1, wherein the outer housing comprises a first aperture locatedalong a first side of the outer housing and a second aperture locatedalong a second side of the outer housing located opposite the firstside, wherein the first aperture and the second aperture are configuredto receive a strap.
 14. The protective face mask of claim 13, whereinthe strap comprises a material that is configured to stretch.
 15. Theprotective face mask of claim 14, wherein the material includes silvernanoparticles.
 16. The protective face mask of claim 1, wherein thereplaceable filter comprises four layers.
 17. The protective face maskof claim 16, wherein the four layers comprise a first sealed filter, aflux filter, a carbon filter, and a second sealed filter.
 18. Theprotective face mask of claim 1, wherein the outer housing defines afirst width and the inner housing defines a second width, wherein thefirst width is larger than the second width.
 19. The protective facemask of claim 1, wherein each hole in the first plurality of ventilationholes defines a first area and each hole in the second plurality ofventilation holes defines a second area, wherein the second area islarger than the first area.
 20. (canceled)
 21. (canceled)
 22. (canceled)23. The protective face mask of claim 1, wherein the replaceable filteris arranged and configured to cover an entire surface of the innerhousing.
 24. The protective face mask of claim 1, wherein the firstportion of the second plurality of ventilation holes and the thirdsecond portion of the second plurality of ventilation holes are arrangedin a honeycomb pattern.
 25. The protective face mask of claim 1, whereinthe outer housing and the inner housing define substantially the sameshape.
 26. The protective face mask of claim 7, wherein the user isconfigured to inhale through the nose via the upper chamber, and exhalethrough the mouth via the lower chamber.